Tufted carpet

ABSTRACT

A tufted carpet has a high density portion and a low density portion. The high density portion has pile yarns implanted into a base fabric with high density. The low density portion has pile yarns implanted into the base fabric with low density. The fiber density of the high density portion is in the range of 280 to 700 g/m 2 . The fiber density of the low density portion is in the range of 200 to 500 g/m 2 . The fiber density of the high density portion is set to a value greater than the fiber density of the low density portion. The difference between the fiber density of the high density portion and the fiber density of the low density portion is set to a value in the range of 30 to 250 g/m 2 .

BACKGROUND OF THE INVENTION

The present invention relates to tufted carpet for use as floor carpet for a vehicle, for example, and includes pile yarns implanted in a base fabric using a tufting machine.

Typically, tufted carpets are formed using a tufting machine. In a tufted carpet, pile yarns extend along a stitch direction of a base fabric with respect to the base fabric. A plurality of rows of pile yarns are arranged along the gauge direction of the base fabric.

The applicant of the present invention has proposed a tufted carpet as described in Japanese Laid-Open Patent Publication No. 2000-239959. The tufted carpet includes pile yarns extending in a stitch direction of a base fabric with respect to the base fabric. A plurality of rows of pile yarns are arranged along a gauge direction of the base fabric. Each of the pile yarn rows is formed by tufting yarn material in a zigzag manner. In this type of tufted carpet, the lines of pile yarns extend loosely in the stitch direction. This improves the appearance of the product.

The tufted carpet may include both a visible portion and a non-visible portion on its outer surface when in use. For example, a floor carpet for a vehicle has both a visible portion and a non-visible portion as viewed from passengers who enter the passenger compartment of the vehicle. In this case, pile yarns are implanted into the visible portion with sufficient density to ensure a desirable appearance for the floor carpet, thus improving the texture of the floor carpet. In contrast, it is desirable to reduce the pile yarns in the non-visible portion in order to decrease the weight of the floor carpet.

In the tufted carpet described in the aforementioned document, yarn streaks of the yarns along the stitch direction are weakened, thus improving the appearance of the carpet. However, since the carpet as a whole is formed in a uniform manner, a visible portion and a non-visible portion as viewed from passengers when in use have equal densities for the pile yarns. As a result, the tufted carpet cannot bring out new advantages caused by the density configuration of the pile yarns.

SUMMARY OF THE INVENTION

Accordingly, it is an objective of the present invention to provide a dense tufted carpet that has improved texture and desirable appearance and is simply configured with reduced weight.

To achieve the foregoing objective and in accordance with one aspect of the present invention, a tufted carpet is provided that includes pile yarns implanted into a base fabric, a high density portion, and a low density portion. The high density portion has the pile yarns implanted into the base fabric with a high density. The low density portion has the pile yarns implanted into the base fabric with a low density.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view showing a tufted carpet according to one embodiment of the present invention;

FIG. 2A is a schematic view showing a tufted carpet having pile yarns implanted into the tufted carpet with both high density and low density;

FIG. 2B is a schematic view showing a tufted carpet having pile yarns implanted with uniform density; and

FIG. 3 is a view schematically illustrating the manufacture of a tufted carpet using a tufting machine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

One embodiment of a tufted carpet according to the present invention will now be described with reference to FIGS. 1 to 3.

As illustrated in FIG. 1, a tufted carpet 10 is formed like a sheet having a rectangular shape as viewed from above. The tufted carpet 10 has a high density portion 13 and a low density portion 14. Pile yarns 12 are implanted with high density in a portion of the base fabric 11 corresponding to the high density portion 13. Pile yarns 12 are implanted with low density in the portion of the base fabric 11 corresponding to the low density portion 14. As illustrated in FIGS. 2A and 2B, the tufted carpet 10 is formed by implanting the pile yarns 12 into the base fabric 11 using a tufting machine. The base fabric 11 is formed of polyester or the like. The pile yarns 12 are formed of nylon (polyamide), polyester, polypropylene or the like. The size of the pile yarns 12 is 900 to 1500 dtex.

In the tufted carpet 10, it is preferable that the fiber density of the high density portion 13, which is the mass of the pile yarns 12, be set to a value in the range of 280 to 700 g/m². It is also preferable that the fiber density of the low density portion 14 be set to a value in the range of 200 to 500 g/m². The fiber density of the high density portion 13 is set to a value greater than the fiber density of the low density portion 14.

A fiber density of the high density portion 13 less than 280 g/m² deteriorates the texture and appearance of the tufted carpet 10 and lowers the quality of the tufted carpet 10. A fiber density of the high density portion 13 exceeding 700 g/m² causes non-uniform implanting of the pile yarns 12 and lowers productivity of the tufted carpet 10. Such fiber density is thus not preferable. A fiber density of the low density portion 14 less than 200 g/m² causes an insufficient implantation amount of the pile yarns 12 and lowers the quality of the tufted carpet 10. Such fiber density is thus not preferable. A fiber density of the low density portion 14 exceeding 500 g/m² is excessively great, so that the low density portion 14 no longer has low density.

With reference to FIG. 2A, the stitch (ST1) of the high density portion 13 is set to a value greater than the stitch (ST2) of the low density portion 14. A stitch (ST) represents the number of the implanted pile yarns 12 per inch. Specifically, it is preferred that the stitch of the high density portion 13 be set to a value in the range of 8.0 to 17.0 and that the stitch of the low density portion 14 be set to a value in the range of 6.0 to 12.0. The stitch of the high density portion 13 is set to a value greater than the stitch of the low density portion 14.

A stitch of the high density portion 13 less than 8.0 cannot achieve the advantages of being a high density portion 13. Specifically, the texture and appearance of the tufted carpet 10 are deteriorated. A stitch of the high density portion 13 exceeding 17.0 causes non-uniform implanting of the pile yarns 12, lowers the production rate for the tufted carpet 10, and is thus not preferable. A stitch of the low density portion 14 less than 6.0 is excessively small and lowers the quality of the tufted carpet 10, which is not preferable. A stitch of the low density portion 14 exceeding 12.0 is excessively great so that the low density portion 14 no longer has low density.

The length (PH) of the pile yarns 12 is set as needed in correspondence with use or purpose of the tufted carpet 10. The gauge (G) is fixed by the base of the tufting machine and normally cannot be changed. The gauge (G) represents the density of the pile yarns 12 in a lateral direction of the tufted carpet 10. A non-illustrated second base fabric or a felt or a film is bonded to the backside of the tufted carpet 10 when necessary.

It is preferable to set the difference between the fiber density of the high density portion 13 and the fiber density of the low density portion 14 to a value in the range of 30 to 250 g/m². If such difference is less than 30 g/m², the advantages of providing the high density portion 13 and the low density portion 14 in the tufted carpet 10 become less significant, and reduction of the weight the tufted carpet 10 becomes insufficient. In contrast, when the difference between the fiber densities exceeds 250 g/m², the high density portion 13 includes an excessively great amount of pile yarns 12 and the low density portion 14 has an insufficient amount of pile yarns 12. This deteriorates the quality of the tufted carpet 10.

An apparatus and a method for manufacturing the tufted carpet 10 will hereafter be described.

As illustrated in FIG. 3, the facility for manufacturing the tufted carpet 10 includes a tufting machine 15, a base fabric roller 16, a pile yarn feeder (a creel) 17, a plurality of guide rollers 18, and a winding roller 19. The tufting machine 15 implants the pile yarns 12 in the base fabric 11. The base fabric 11 is wound around the base fabric roller 16. The pile yarn feeder 17 feeds pile yarns (yarn material). The winding roller 19 winds the tufted carpet 10. The tufting machine 15 receives the base fabric 11 from the base fabric roller 16 and the pile yarns 12 from the pile yarn feeder 17. The tufting machine 15 implants the pile yarns 12 in the base fabric 11 by means of needles in the stitch direction and the gauge direction.

The tufting machine 15 moves the base fabric 11 slowly when forming the high density portion 13, compared to when forming the low density portion 14. This forms the high density portion 13 in the tufted carpet 10. In other words, the implantation amount of the pile yarns 12 is increased by maintaining the speed constant at which the needles implant the pile yarns 12 and reducing the speed at which the base fabric 11 is moved. As a result, the above-described high density portion 13 is formed.

The operation of a machine for producing the tufted carpet 10 will hereafter be described.

To manufacture the tufted carpet 10 having the high density portion 13 and the low density portion 14 as illustrated in FIG. 3, the tufting machine 15 operates in the manner described below. Specifically, the feeding speed of the base fabric 11 output by the base fabric roller 16 is decreased when the high density portion 13 is being formed, compared to the feeding speed of the base fabric 11 at the time when the low density portion 14 is being formed. In other words, when the tufting machine 15 is forming the low density portion 14, the feeding speed of the base fabric 11 slows down as the pile yarns 12 are implanted continuously in the base fabric 11. In this manner, in the procedure for manufacturing the tufted carpet 10, the high density portion 13 is formed subsequent to the low density portion 14.

The tufted carpet 10, which is obtained in the above-described manner, has the high density portion 13 having pile yarns 12 implanted with high density and the low density portion 14 having pile yarns 12 implanted with low density. As a result, the pile yarns 12 implanted with the high density ensure denseness, improved texture, and desirable appearance of the high density portion 13. In contrast, the pile yarns 12 implanted with the low density decreases the weight and ensures simple configuration of the low density portion 14. The tufted carpet 10 may be used as, for example, a floor carpet for a vehicle. Specifically, the tufted carpet 10 is used with the high density portion 13 arranged at a position to be visible and the low density portion 14 arranged at a position to be visible.

More specifically, as represented by Table 1, the gauge (G) was set to 1/10 in Examples 1, 2, and 3. In other words, the gauge (G) was set in such a manner that ten pile yarns 12 existed per inch. Then, the tufted carpet 10 was manufactured by setting the stitch (ST1) of the high density portion 13, the stitch (ST2) of the low density portion 14, the height (PH) of each pile yarn 12, and the fiber density as represented in Table 1. As a result, by increasing the density of the pile yarns 12, improved texture and desirable appearance were obtained in the high density portion 13. In contrast, by decreasing the density of the pile yarns 12, simple configuration and weight reduction were ensured in the low density portion 14.

TABLE 1 ST PH Fiber Density G (Piles/Inch) (mm) (g/m²) Example 1 1/10 ST1 12.5 5.5 360 1/10 ST2 9.4 5.5 285 Example 2 1/10 ST1 14.8 6.0 450 1/10 ST2 8.1 6.0 270 Example 3 1/10 ST1 14.1 5.5 400 1/10 ST2 8.0 5.5 250

The illustrated embodiment has the advantages described below.

(1) The tufted carpet 10 has the high density portion 13 and the low density portion 14. The high density portion 13 has an improved texture and a desirable appearance ensured by the pile yarns 12 implanted with a high density. In contrast, the low density portion 14 is reduced in weight by the pile yarns 12 implanted with a low density. This configuration provides a tufted carpet 10 that is dense, improved in texture and appearance, expensive looking, simply configured, and light-weight.

(2) The fiber density of the high density portion 13 is in the range of 280 to 700 g/m². The fiber density of the low density portion 14 is in the range of 200 to 500 g/m². The fiber density of the high density portion 13 is set to a value greater than the fiber density of the low density portion 14. This ensures a sufficiently great difference between the fiber density of the high density portion 13 and the fiber density of the low density portion 14. As a result, the above-described advantages are brought about by the high density portion 13 and the low density portion 14.

(3) The stitch of the high density portion 13 is in the range of 8.0 to 17.0. The stitch of the low density portion 14 is in the range of 6.0 to 12.0. The stitch of the high density portion 13 is a value greater than the stitch of the low density portion 14. In this configuration, the stitch of the high density portion 13 and the stitch of the low density portion 14 are both adequate. As a result, the respective advantages of the high density portion 13 and the low density portion 14 are each ensured. Also, the pile yarns 12 are smoothly implanted into the base fabric 11.

(4) The difference between the fiber density of the high density portion 13 and the fiber density of the low density portion 14 is set to a value in the range of 30 to 250 g/m². This ensures a clear difference in fiber density between the high density portion 13 and the low density portion 14. As a result, the respective advantages of the high density portion 13 and the low density portion 14 are each brought about effectively.

(5) The high density portion 13 is formed in the tufted carpet 10 by reducing the movement speed of the base fabric 11 in the tufting machine 15 compared to the feeding speed of the base fabric 11 at the time when the low density portion 14 is being formed. In other words, the high density portion 13 is easily formed simply by changing the feeding speed of the base fabric 11.

The above described embodiment may be modified as follows.

A single tufted carpet 10 may include a plurality of high density portions 13 and a plurality of low density portions 14. In this case, the sizes of the high density portions 13 and the sizes of the low density portions 14 may be changed as needed in correspondence with the intended purpose.

The fiber densities or the stitches of the high density portion 13 and the low density portion 14 may be set as needed in correspondence with the size or the length of each pile yarn 12.

A middle density portion may be arranged between the high density portion 13 and the low density portion 14. Specifically, the middle density portion has a density between the density of the pile yarns 12 forming the high density portion 13 and the density of the pile yarns 12 forming the low density portion 14. 

1. A tufted carpet comprising: pile yarns implanted into a base fabric; a high density portion having the pile yarns implanted into the base fabric with a high density; and a low density portion having the pile yarns implanted into the base fabric with a low density.
 2. The tufted carpet according to claim 1, wherein: the fabric density of the high density portion is in the range of 280 to 700 g/m²; the fabric density of the low density portion is in the range of 200 to 500 g/m²; and the fabric density of the high density portion is set to a value greater than the fabric density of the low density portion.
 3. The tufted carpet according to claim 1, wherein: the stitch of the high density portion is in the range of 8.0 to 17.0; the stitch of the low density portion is in the range of 6.0 to 12.0; and the stitch of the high density portion is set to a value greater than the stitch of the low density portion.
 4. The tufted carpet according to claim 1, wherein the difference between the fiber density of the high density portion and the fiber density of the low density portion is in the range of 30 to 250 g/m².
 5. The tufted carpet according to claim 1, wherein the high density portion of the tufted carpet is formed by making the speed for moving the base fabric in a tufting machine lower than the speed for moving the base fabric at the time when the low density portion is being formed. 